Thomas Yap, Ph.D., P.E., MBA, PMP, CWI
Principal Consultant
SERVICES GROUP
LOCATION
Get to know the expert
Expert QuestionS & AnswerS
When investigating mechanical or equipment failures, how do you determine whether the root cause was a design deficiency, manufacturing defect, or improper maintenance?
I begin by preserving evidence and reconstructing the sequence of events. I compare the failed equipment with drawings, specifications, codes, operating data, maintenance records, and similar components. A design deficiency appears when expected loads or operating conditions were not adequately addressed. A manufacturing defect is indicated by material or fabrication deviations, while improper maintenance is supported by wear, missed inspections, incorrect adjustments, or undocumented repairs.
What is the most common mistake parties make early in a industrial and renewable energy matter that complicates the investigation later?
The most common mistake is altering the scene before the evidence is fully documented and preserved. Parties may repair or discard failed components, reset equipment, or overwrite PLC, SCADA, alarm, and operating data. They may also delay interviewing witnesses while memories are fresh. Once physical evidence or time-sensitive data is lost, it becomes much harder to reconstruct the sequence of events and distinguish the initiating cause from damage that occurred afterward.
What is a case finding in your career that challenged a widely held assumption in industrial and renewable energy?
A radial stacker collapse I evaluated challenged the belief that automated controls would safely stop the machine in high winds. The investigation revealed a design deficiency: the brakes were not adequately sized for the specified wind loads, and the software and encoders could not overcome that limitation or missing field safeguards. The case reinforced that automation does not make equipment fail-safe; mechanical design, control logic, installation, and actual loads must work as one system.
What is the most interesting case you’ve worked on that you can talk about without revealing client details?
One of my most interesting cases involved a natural-gas explosion in Avondale, Louisiana. As a pipeline operations and safety expert, I evaluated damaged 2-inch gas-main components, incident timeline, utility response, dashcam footage, and a 3D scene model. Without discussing the parties or final causation opinions, the case was compelling because it required connecting physical pipe evidence, potential gas-migration pathways, vehicle movement, and emergency response to reconstruct the event.
What is the simplest change a building owner can make that has the biggest impact on energy efficiency?
For many buildings, the simplest high-impact change is matching HVAC operation to actual occupancy. Owners should review thermostat setpoints and schedules so heating, cooling, and ventilation are reduced when spaces are unoccupied, while maintaining humidity control and equipment safety. This costs little compared with major upgrades and often reveals equipment running unnecessarily overnight or on weekends. The next step is sealing obvious air leaks and keeping filters and coils clean.
Background
Dr. Thomas Yap is a forensic mechanical engineer and licensed Professional Engineer with over 25 years of experience in energy, oil and gas, heavy industry, and industrial systems. He is licensed in 12 U.S. states, reflecting a broad multi-jurisdictional engineering practice. He specializes in failure analysis, root cause investigations, and engineering evaluations involving complex mechanical systems, pressure equipment, rotating machinery, pressure piping systems, welding, and process facilities.
Dr. Yap provides technical expertise in high-consequence incidents, including explosions, fires, equipment failures, structural collapses, welding-related failures, and industrial accidents. His forensic work spans power generation, petrochemical facilities, pipelines, hydrogen systems, wastewater treatment facilities, renewable energy projects, and heavy manufacturing environments. He supports litigation matters through engineering analysis, failure reconstruction, causation evaluations, and expert opinion development.
His expertise includes pressure vessels, heat exchangers, compressors, hydraulic and pneumatic systems, cranes and lifting equipment, drilling systems, pressure piping systems, welding inspections, and other pressure-containing equipment. His experience spans a wide range of industrial applications, including refineries, boiler and burner systems, power plants, oil rigs, pipelines, wastewater treatment facilities, anaerobic digester tanks, vacuum trucks, septic systems, and renewable energy technologies.
He has led and supported investigations involving boiler explosions, pipeline failures, structural collapses, rotating equipment damage, pressure boundary failures, welding-related failures, and hydrogen-related incidents. His work includes evaluation of design, operation, maintenance, fabrication, inspection, and installation factors, as well as determination of causation and contributing factors in complex failure events.
Dr. Yap has held engineering and leadership roles with major energy and industrial organizations, including General Electric, Hitachi, Nel Hydrogen, Cameron (a Schlumberger company), Forum Energy Technologies, Loadmaster, and Favelle Favco. His experience includes the design and evaluation of complex systems such as nuclear reactors, choke and kill manifolds, offshore cranes, tower cranes, pressure vessels, hydrogen electrolyzer systems, and drilling equipment.
In addition to his forensic engineering practice, Dr. Yap possesses extensive technical expertise in energy systems and sustainability. His background includes renewable energy technologies such as hydrogen fuel cells, solar, wind, hydroelectric, geothermal, and biomass systems, as well as advanced carbon management technologies including Carbon Capture and Storage (CCS) and Carbon Capture, Utilization, and Storage (CCUS). He has conducted research and techno-economic evaluations related to advanced energy technologies, hydrogen infrastructure, and energy system integration.
He applies a wide range of industry codes and standards, including ASME, API, AWS, ANSI, AISC, ABS, and DNV standards. His experience includes ASME B31.1, B31.3, B31.8, ASME Section III and VIII, API 2C, API 4F, API 6A, API 8C, API 9A, API 16C, API 1104, API STD 53, and AWS welding codes and standards. As a Certified Welding Inspector (CWI), he evaluates welding integrity, fabrication quality, inspection programs, and compliance with applicable codes and standards in both industrial and forensic applications.
Dr. Yap holds a Ph.D. in Energy Engineering with specialization in hydrogen fuel cell systems, techno-economic analysis, and advanced energy technologies. His doctoral research focuses on techno-economic analysis and Density Functional Theory (DFT) modeling of platinum-based hydrogen fuel cell catalysts for long-range electric vehicle applications. His research and interdisciplinary background enhance his ability to evaluate complex engineering systems, energy technologies, and industrial failures from both technical and economic perspectives.
Languages: Mandarin/Chinese, English, Malay, Cantonese, Hokkien
Education and Certifications
- Energy Engineering, Ph.D.: University of North Dakota (2023-2026)
- MBA (General): University of Houston-Victoria (2021)
- Mechanical Engineering, BEng (Hons): Universiti Teknologi Malaysia (2000)
- Licensed Professional Engineer: Alabama, Arkansas, California, Colorado, Florida, Louisiana, Minnesota, Mississippi, Montana, Oklahoma, and Texas
- PMP: No: 3637906
- Certified Welding Inspector (CWI) QC-1: Certificate Number 09072391
- Institution of Engineers Malaysia (MIEM): Member
- Professional Engineer, Title: Ir. (Member of Board of Engineers Malaysia)
- Associate Member of Institute of Mechanical Engineer (AMIMechE), United Kingdom
- OSHA Training: OSHA 30-Hr Certification
Publications
- Song, F., Li, K., Rivas, C. S., Bieneman, K., & Yap, T. (2020). Multidisciplinary Optimization-Enabled Design Automation and Optimization for Blowout Preventer Pipe Rams. Paper No: IMECE2020-24109, V006T06A040. ASME Digital Collection.
- Josephs, R., Yap, T. C., Alamooti, M., Omojiba, T., Benarbia, A., Tomomewo, O. S., & Ouadi, H. (2025). Regulation of small modular reactors (SMRs): Innovative strategies & economic insights. Eng.
- Yap, T. C. (2025). A Review of Techno-Economic Analysis and Density Functional Theory Modeling of Hydrogen Fuel Cells with Platinum-Based Catalysts for Effective Deployment in Long-Range Electric Vehicles. International Journal of Hydrogen Energy, Article Ref: HE49427.